Recycled tire paver blocks

ABSTRACT

Recycled tire paver blocks with hidden interconnectors are cast blocks composed at least of a binder and rubber, the rubber being shredded rubber from recycled tires. The block has a top, a bottom and at least one sidewall, and has a substantially symmetric shape from a top view. It has at least one protruding male interconnector located on and extending outwardly from the at least one sidewall, and having at least one female interconnector located under the block on its bottom, at least 90 degrees away from the male interconnector as measured in an arc from a centerpoint of the block. The at least one female interconnector is a recess adapted to receive a male interconnector of a similar block. When the paver block male interconnector is inserted into a female interconnector of a similar block, both interconnectors are significantly hidden from top view.

BACKGROUND OF INVENTION

a. Field of Invention

The invention relates generally to recycled tire paver blocks (alsocalled patio blocks) that may be used for any paver application,including walkways, patios, pools and landscape treatments, as well asother applications, such as paddock pathways, and exercise and gymareas. By “pavers” is meant blocks that are designed to interfit, likebricks or patio blocks, to create a pattern or array of units toaccommodate different size areas that are typically walked upon. Thepresent invention recycled tire paver blocks have unique constructionand hidden interconnectors. The pavers are composed of binder(s),optional colorant and shredded rubber. The shredded rubber, also knownas crumb rubber, is made predominantly of recycled shredded rubber andis preferably entirely shredded rubber from used, recycled tires.

b. Description of Related Art

The following patents are representative of the field of this invention:

U.S. Pat. No. 7,344,334 B2 to Thorkelson describes a paver system thatcomprises of a plurality of paver pieces and at least one substrate.Each of the paver pieces has a top surface and a bottom surface. Thebottom surface of the paver pieces is configured for mating with theupper surface of the substrate, whereby paver pieces coupled to thesubstrate are prevented from moving laterally.

U.S. Pat. No. 7,300,032 B2 to Williams et al. describes a crumb rubberbase pad which is for supporting mechanical machines and equipment andwhich is configured such that it reduces the noise and vibrationemanating from these machines. The pad is constructed entirely fromshredded and comminuted rubber tires and is configured such that itprovides for the efficient run-off and/or draining of any moisturegenerated from under the machine unit.

U.S. Pat. No. 6,185,893 B1 to Gaston describes a paving block system andcorresponding components and methods. The system finds particularlyefficacious application in forming patios, walkways and driveways, andmay comprise interconnecting or adjoining bottom barriers and sidebarriers. Each bottom barrier receives one or more paving blocksthereon, and may optionally have formed in the bottom surface thereof arecess for receiving a top rail formed into the bottom barrier. Inpreferred embodiments of the present invention, adjoining blocksinterconnect to form a relatively continuous paving block top surface.The present invention permits the effects of undesired displacementforces acting on the blocks, such as frost heave, to be reduced orminimized, and further permits a user to install a driveway, walkway orpatio relatively rapidly.

U.S. Pat. No. 5,468,539 to Crivelli describes a rubber tire recyclingprocess that comprises the steps of granulating black rubber tire sidewalls and treads and granulating white rubber tire side walls to formcoarse rubber crumbs, mixing the coarse rubber crumbs with fine clayparticles to form a closely packed mixture, thoroughly wetting thesurfaces of the coarse particles with an uncured EPDM rubber to providea fluid, casting the fluid into a sheet-like configuration, and curingthe sheet-like configuration under sufficient heat and for a sufficienttime to provide an environmentally compatible paver for outdoor orindoor surfaces.

U.S. Pat. No. 5,258,222 to Crivelli describes a rubber tire recyclingprocess that comprises the steps of granulating rubber tires to formcoarse rubber crumbs, mixing the coarse rubber crumbs with coarsesiliceous grains to form a closely packed mixture of coarse particlesthat are roughly commensurate in size, thoroughly wetting the surfacesof the coarse particles with a polymerizable liquid binder to provide anenvironmentally compatible sheet-like product, e.g. a paver or tile fordriveways, or a shingle for roof tops, that is characterized byexcellent weather, wear and chemical resistance. The surfacecharacteristics of the coarse particles of vulcanized rubber andcrystalline grains are critical to the present invention.

U.S. Pat. No. 3,842,562 to Daigle describes precast concrete slabs thatare joined together to form a walk or patio-like matrix by embedding aplurality of rods in each slab and providing cavities in the bottomfaces of each slab. Each rod has a hooked end portion which projectsbeyond opposing end walls of the slab, the hooked end portions and thecavities being positioned such that the hooked end portions of one slabare receivable in the cavities of another slab, whereby the slabs may beinterlocked end to end to form a strip of slabs. Similar cavities androds having hooked ends may be positioned in each slab at right anglesto the aforementioned rods and cavities to permit sidewise connectionsof the slabs along with end-to-end connection.

Notwithstanding the prior art, the present invention is neither taughtnor rendered obvious thereby.

SUMMARY OF THE INVENTION

The present invention relates to recycled tire paver blocks with hiddeninterconnectors. The present invention is a cast block being composed atleast of a binder and rubber, the rubber being shredded rubber fromrecycled tires. The present invention is a cast block, and preferably aheat fused, cast paver block, that has a top, a bottom and at least onesidewall, the block having a substantially symmetric shape from a topview (at least symmetric as to one axis), and having at least oneprotruding male interconnector located on and extending outwardly fromthe at least one sidewall, and having at least one female interconnectorlocated under the block on its bottom, at least 90 degrees away from themale interconnector as measured in an arc from a centerpoint of theblock. The at least one female interconnector is a recess adapted toreceive a male interconnector of a similar block. When the paver blockmale interconnector is inserted into a female interconnector of asimilar block, both interconnectors are significantly hidden (at least90% hidden) from top view.

In some preferred embodiments of the present invention recycled tirepaver block with hidden interconnectors, there are at least two maleinterconnectors and at least two female interconnectors.

In some preferred embodiments of the present invention recycled tirepaver block with hidden interconnectors, each male interconnector has asymmetrically opposite female interconnector.

In some preferred embodiments of the present invention recycled tirepaver block with hidden interconnectors, the cast block has a top viewshape selected from the group consisting of circle, oval, square,rectangle, polygon and combinations thereof.

In some preferred embodiments of the present invention recycled tirepaver block with hidden interconnectors, each of the at least one femaleinterconnector includes and open bottom horizontal slot and an upwardrecess.

In some preferred embodiments of the present invention recycled tirepaver block with hidden interconnectors, each of the at least one maleinterconnector includes an outwardly extending portion and an upcropextending upwardly.

In some preferred embodiments of the present invention recycled tirepaver block with hidden interconnectors, at least one side includes atleast two male interconnectors and at least one side includes two femaleinterconnectors.

In some preferred embodiments of the present invention recycled tirepaver block with hidden interconnectors, the block includes at least oneembossed design on the top.

Additional features, advantages, and embodiments of the invention may beset forth or apparent from consideration of the following detaileddescription, drawings, and claims. Moreover, it is to be understood thatboth the foregoing summary of the invention and the following detaileddescription are exemplary and intended to provide further explanationwithout limiting the scope of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate preferred embodiments of theinvention and together with the detail description serve to explain theprinciples of the invention. In the drawings:

FIG. 1 illustrates a top view of present invention recycled tire paverblock having a square configuration with two male interconnectors andtwo female interconnectors, and FIGS. 2 and 3 show side and bottom viewsthereof, respectively. FIGS. 1, 2 and 3 are top, side and bottom views,respectively, of one embodiment of a present invention paver block;

FIG. 4 shows a partially cut side view of a plurality of presentinvention recycled tire paver blocks of the type shown in FIGS. 1, 2 and3 above with adjacent blocks having male and female interconnectorsconnected to one another;

FIGS. 5 illustrates a top view of present invention recycled tire paverblock having an octagonal configuration with two male interconnectorsand two female interconnectors;

FIG. 6 shows a top view of a paver block insert that may be used withinterconnected blocks of the type shown in FIG. 5;

FIG. 7 shows a partially top view of a plurality of present inventionrecycled tire paver blocks and inserts of the types shown in FIGS. 5 and6 above with adjacent blocks having male and female interconnectorsconnected to one another;

FIGS. 8 and 9 show a top view and a side view of a present inventionpaver block with embossed designs thereon;

FIG. 10 shows a top view of a plurality of present invention recycledtire paver blocks of the type shown in FIGS. 8 and 9 above with adjacentblocks having male and female interconnectors connected to one anotherto create a linear pattern of blocks;

FIG. 11 shows a top view of one embodiment of a present inventionrecycled tire paver block having a square configuration with sets ofdual interconnectors on each side to allow for either adjacent or halfoffset adjacent connections;

FIGS. 12 shows a top view of a plurality of present invention recycledtire paver blocks of the type shown in FIG. 11 above with adjacentblocks having male and female interconnectors connected to one anotherto create a staggered pattern of blocks;

FIG. 13 shows a top view of a plurality of present invention recycledtire paver blocks of circular shape;

FIGS. 14 a and 14 b illustrate identical shifted double rectangle blocksof the present invention; and,

FIG. 15 shows a plurality of the present invention FIG. 14 a and l4 bblocks interconnected.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Used tires are recycled by being macerated mechanically through a seriesof cutters with increasingly smaller pieces being produced, from fulltires, to tires with sidewall beads removed, to 9″ to 12″ pieces, to 3′to 5″ pieces, down to an inch or less and then to smaller sizes that aretenths of an inch or less. Centrifuges or other processes remove fiberfrom rubber and magnets remove metal fines. The resulting crumb rubberis utilized as the major constituent in forming the products of thepresent invention. The crumb rubber is mixed with a binder and themixture may include other additives, such as colorants and flameretardants. Binders may be thermoset plastics, polyvinyl chloride,urethane or other material, or combinations thereof.

The crumb rubber and binder (and other constituents, where applicable)are cold blended or hot blended and then molded into the shape of thefinished paver blocks of the present invention. The molding process maybe hot melt molding and hot pressure molding is preferred. The mixtureis poured into an open mold and pressed into the mold with predeterminedheat and pressure. The heat is typically below the melting point of thecrumb rubber in terms of temperature and exposure time, but in somepreferred embodiments, sufficient heating is applied to fuse the binderand crumb rubber particles together. The molded products are ejected orremoved from the molds manually or automatically using ejector systems.

FIG. 1 illustrates a top view of present invention paver block 1, andFIGS. 2 and 3 show side and bottom views thereof, respectively. In theFIGS. 1, 2 and 3, identical elements are identically numbered and theseFigures are now discussed collectively.

Block 1 has a top 3, a bottom 5, and sides 7, 9, 11 and 13. Top 3 isshown as a smooth flat surface, not could be embossed, painted orotherwise embellished. Two adjacent sides 7 and 9 have maleinterconnectors 15 and 19, respectively. These male interconnectors havea tongue portion and a locking upcrop, shown as upcrop 17 and 21 on maleinterconnectors 15 and 19, respectively (FIG. 2 shows the side profileof male interconnector 19).

At about 90° from male interconnector 19 on side 11 is femaleinterconnector 27. Female interconnector 27 is a slot with a deeperupward recess 29, adapted to receive a male upcrop, similar or identicalto upcrop 21 of male interconnector 19. Similarly, on side 13 is asecond female interconnector 23 with upward recess 25, likewise adaptedto receive a corresponding male interconnector. FIG. 2 shows an entryview and a side profile of female interconnectors 27 and 23, and bottomview FIG. 3 shows the bottom views of these female interconnectors.

Referring now to FIG. 4, there is shown a side view of present inventionpaver block 1, in a partial cut view, with identical present inventionpaver block 10 connected thereto. This Figure shows how the presentinvention paver blocks interconnect. Block 1 has identical elementsidentically numbered as above. Block 10 has female interconnectors 12and 14 and two male interconnectors (are not shown). Male interconnector16 of block 10 fits into female interconnector 23 of block 1. In thismanner, the two blocks are interlocked and fixed as to relativepositions, spacing, angle and cannot easily be separated from oneanother by sliding or incidental pushing when walked upon. Further,these blocks are available for additional connections on each of theirthree open (unconnected) sides. End blocks of an array or arrangementmay have male interconnectors such as male interconnector 19 or FIG. 4,exposed. It may be buried or it may be cut off using a saw, such assheetrock or gypsum board saw or keyhole saw or using a serrated knife.However, burying exposed male interconnectors could add more stabilityto end pieces.

FIG. 5 shows a top view of another present invention paver block 40 madefrom recycled tire crumb rubber in the process described above. Block 40has a top 43 with “cut” corners to create an octagon. Thus, block 40 haseight sides, that include major sides 47, 49, 51, 53, and corner sides71, 73, 75 and 77. Two adjacent major sides 47 and 49 have maleinterconnectors 55 and 59, respectively. These male interconnectors havea tongue portion and a locking upcrop, shown as upcrops 57 and 61 onmale interconnectors 55 and 59, respectively (FIG. 2 shows the sideprofile of the type of male interconnector used here). At about 90° frommale interconnector 59 on major side 59 is female interconnector 67.Female interconnector 67 is a slot with a deeper upward recess 69,adapted to receive a male upcrop, similar or identical to upcrop 61 ofmale interconnector 59. Similarly, on major side 53 is a second femaleinterconnector 63 with upward recess 65, likewise adapted to receive acorresponding male interconnector.

FIG. 6 shows a top view of a paver block insert 50 that would fill inthe spaces created when a plurality of blocks of the octagon type ofFIG. 5 are assembled together. Thus, paver insert 50 has four equalsides 83, 85, 87 and 89 that would be contiguous to four differentconnected blocks (block 40 of FIG. 5), with top 81 having the same ofdifferent characteristics (color, hue, topography, grain size,embossment, print) as the tops of the contiguous present invention paverblocks.

FIG. 7 shows a top view of a plurality of present invention pavers withthe FIG. 6 type interconnectors, installed. Thus, present inventionpaver blocks 101, 103, 105, 107 and 109 are similar to block 40 of FIG.5 and are all interconnected in a manner similar to that shown in FIG.4. On the outer top and right peripheries of these present inventionpaper blocks would be unused, extended male interconnectors. However, asindicated above, they could easily be cut or sawed off. Alternatively,they could be left in place and buried such as under earth and grass 100of FIG. 7.

FIG. 8 shows a top view and FIG. 9 shows a side view of another presentinvention paver block 130 made from recycled tire crumb rubber in theprocess described above. FIGS. 8 and 9 are now described collectively.Block 130 has a top 131 with a central circular raised embossment design133 and quarter circle raised corner embossments, such as embossments135 and 137. Present invention paver block 130 has four equal sides 139,141, 143 and 145, but these could be unequal in the form, for example,of a rectangle instead of a square. Two adjacent sides 143 and 145 havemale interconnectors 151 and 147, respectively. These maleinterconnectors have a tongue portion and a locking upcrop, shown asupcrops 153 and 149 on male interconnectors 151 and 147, respectively(FIG. 2 shows the side profile of the type of male interconnector usedhere). At about 900 from male interconnector 147 on side 139 is femaleinterconnector 161 with upward recess 163. Female interconnector 161 isthus a horizontal slot with a deeper upward recess 163, adapted toreceive a male upcrop, similar or identical to upcrop 153 of maleinterconnector 151. Similarly, on side 141 is a second femaleinterconnector 155 with upward recess 157, likewise adapted to receive acorresponding male interconnector.

FIG. 10 shows a top view of a plurality of present invention pavers withthe FIGS. 8 and 9 type interconnectors, installed. Thus, presentinvention paver blocks 130, 140, 150, 160, 170 and 180 are the same asblock 130 of FIGS. 8 and 9 and are all interconnected in a mannersimilar to that shown in FIG. 4. On the outer top and left peripheriesof these present invention paper blocks would be unused, extended maleinterconnectors. However, as indicated above, they could easily be cutor sawed off. Alternatively, they could be left in place and buried suchas under earth and grass 132 of FIG. 10.

FIG. 11 shows of another present invention paver block 190 similar tothe one shown in FIG. 8 above, except for the interconnectorarrangements. This block 190 is made from recycled tire crumb rubber inthe process described above. Block 190 has a top 191 with a centralcircular raised embossment design 193 and quarter circle raised cornerembossments, such as embossments 195 and 197. Any design could be usedand the embossment could be raised, recessed or a combination thereof.Present invention paver block 190 has four equal sides 199, 201, 203 and205, but these could be unequal in the form, for example, of a rectangleinstead of a square. Each of two adjacent sides 143 and 145 have twomale interconnectors 207 and 211, and 215 and 219, respectively. Thesemale interconnectors have a tongue portion and a locking upcrop, shownas upcrops 209, 211, 217 and 223 on male interconnectors 207, 213, 215and 219, respectively (FIG. 2 shows the side profile of the type of maleinterconnector used here).

As can be seen in this FIG. 11, the pairs of male interconnectors on agiven side are located at about ¼ and ¾ of the length of the side. Thispositioning allows for staggered (shifted) interconnection, as shown inFIG. 12 below. At about 90° from male interconnectors 215 and 219 onside 203 are female interconnectors 225 and 229 with upward recesses 227and 231. A similar set of female interconnectors (unnumbered) arelocated on side 199. All of the female interconnectors are adapted toreceive the corresponding male interconnectors of adjacent identical orsimilar blocks.

FIG. 12 shows a top view of a plurality of staggered present inventionpavers with the FIG. 11 type dual sets of interconnectors, installed.Thus, present invention paver blocks 190, 200, 210, 220 and 230 are thesame as block 190 of FIG. 11 and are all interconnected, offset by halfa length, in a manner similar to that shown in FIG. 4. On some of theperipheries of these present invention paper blocks would be unused,extended male interconnectors. However, as indicated above, they couldeasily be cut or sawed off. Alternatively, they could be left in placeand buried such as under earth and grass or any other ground or groundcoverings.

FIG. 13 shows a top view of a plurality of present invention recycledtire paver blocks of circular shape. Each of these blocks has two maleand two female interconnectors. Block 240 illustrates the arrangement.It has male interconnectors 243 and 245 and female interconnectors 247and 249. These correspond and lock into each other. Thus, blocks 240,250, 260 and 270 are connected to one another with the interconnectors,as shown.

FIGS. 14 a and 14 b illustrate identical shifted double rectangle blocks310 and 320 of the present invention. The blocks are shown in adjacentFigures even though they are identical so that there potentialinterconnection can be more easily seen. Block 310 in FIG. 14 a andblock 320 of FIG. 14 b each has a top view footprint that is equivalentto two identical rectangles being next to and touching and thenstaggering one a half length upwardly and away from the other, andhence, is referred to as a shifted double rectangle. Block 310 incluxxx

FIG. 15 shows a plurality of the present invention FIG. 14 a and 14 bblocks interconnected.

Although particular embodiments of the invention have been described indetail herein with reference to the accompanying drawings, it is to beunderstood that the invention is not limited to those particularembodiments, and that various changes and modifications may be effectedtherein by one skilled in the art without departing from the scope orspirit of the invention as defined in the appended claims. For example,in some preferred embodiments, before being melted and fused, theshredded rubber from used tires may be intermixed with an appropriatebinding material, such as those used in the insides of a baseball, orany other available binder that works with rubber used in tires.

1. A recycled tire paver block with hidden interconnectors, whichcomprises: a cast block having a top, a bottom and at least onesidewall, said block having a substantially symmetric shape from a topview, and having at least one protruding male interconnector located onand extending outwardly from said at least one sidewall, and having atleast one female interconnector located under said block on its bottom,at least 90 degrees away from said male interconnector as measured in anarc from a centerpoint of said block, said at least one femaleinterconnector being a recess adapted to receive a male interconnectorof a similar block, said block being composed at least of a binder andrubber, said rubber being shredded rubber from recycled tires; such thatwhen said paver block male interconnector is inserted into a femaleinterconnector of a similar block, both interconnectors aresignificantly hidden from top view.
 2. The recycled tire paver blockwith hidden interconnectors of claim 1 wherein there are at least twomale interconnectors and at least two female interconnectors.
 3. Therecycled tire paver block with hidden interconnectors of claim 2 whereineach male interconnector has a symmetrically opposite femaleinterconnector.
 4. The recycled tire paver block with hiddeninterconnectors of claim 1 wherein said cast block has a top view shapeselected from the group consisting of circle, oval, square, rectangle,polygon and combinations thereof.
 5. The recycled tire paver block withhidden interconnectors of claim 1 wherein each of said at least onefemale interconnector includes an open bottom horizontal slot and anupward recess.
 6. The recycled tire paver block with hiddeninterconnectors of claim 1 wherein each of said at least one maleinterconnector includes an outwardly extending portion and an upcropextending upwardly.
 7. The recycled tire paver block with hiddeninterconnectors of claim 5 wherein each of said at least one maleinterconnector includes an outwardly extending portion and an upcropextending upwardly.
 8. The recycled tire paver block with hiddeninterconnectors of claim 1 wherein at least one side includes at leasttwo male interconnectors and at least one side includes two femaleinterconnectors.
 9. The recycled tire paver block with hiddeninterconnectors of claim 5 wherein at least one side includes at leasttwo male interconnectors and at least one side includes two femaleinterconnectors.
 10. The recycled tire paver block with hiddeninterconnectors of claim 1 wherein said block includes at least oneembossed design on said top.
 11. A recycled tire paver block with hiddeninterconnectors, which comprises: a cast, heat fused block having a top,a bottom and at least one sidewall, said block having a substantiallysymmetric shape from a top view, and having at least one protruding maleinterconnector located on and extending outwardly from said at least onesidewall, and having at least one female interconnector located undersaid block on its bottom, at least 90 degrees away from said maleinterconnector as measured in an arc from a centerpoint of said block,said at least one female interconnector being a recess adapted toreceive a male interconnector of a similar block, said block beingcomposed at least of a binder, a colorant and rubber, said rubber beingshredded rubber from recycled tires; such that when said paver blockmale interconnector is inserted into a female interconnector of asimilar block, both interconnectors are significantly hidden from topview.
 12. The recycled tire paver block with hidden interconnectors ofclaim 11 wherein there are at least two male interconnectors and atleast two female interconnectors.
 13. The recycled tire paver block withhidden interconnectors of claim 12 wherein each male interconnector hasa symmetrically opposite female interconnector.
 14. The recycled tirepaver block with hidden interconnectors of claim 11 wherein said castblock has a top view shape selected from the group consisting of circle,oval, square, rectangle, polygon and combinations thereof.
 15. Therecycled tire paver block with hidden interconnectors of claim 11wherein each of said at least one female interconnector includes an openbottom horizontal slot and an upward recess.
 16. The recycled tire paverblock with hidden interconnectors of claim 11 wherein each of said atleast one male interconnector includes an outwardly extending portionand an upcrop extending upwardly.
 17. The recycled tire paver block withhidden interconnectors of claim 15 wherein each of said at least onemale interconnector includes an outwardly extending portion and anupcrop extending upwardly.
 18. The recycled tire paver block with hiddeninterconnectors of claim 11 wherein at least one side includes at leasttwo male interconnectors and at least one side includes two femaleinterconnectors.
 19. The recycled tire paver block with hiddeninterconnectors of claim 15 wherein at least one side includes at leasttwo male interconnectors and at least one side includes two femaleinterconnectors.
 20. The recycled tire paver block with hiddeninterconnectors of claim 11 wherein said block includes at least oneembossed design on said top.